2015-2017 Polaris Ranger XP/CREW 570/900/1000 OEM Service & Repair Manual

FOREWORD The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com. This Service Manual is designed primarily for use by certified Polaris Master Service Dealer ® technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service Manual, contact an authorized dealer for service. We value your input and appreciate any assistance you can provide in helping make these publications more useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'. Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department, 2100 Hwy 55, Medina, MN 55340. Publication Printed August 2016 (PN 9927645 R04) © Copyright 2016 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2015–2017 RANGER XP/CREW 570/900/1000 Service Manual

SAFETY WARNINGS Throughout this manual, important information is brought to your attention by the following symbols: WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle. CAUTION CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage. NOTE NOTE provides key information by clarifying instructions. IMPORTANT IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer. REVISION INDEX REV DATE CHANGES R01 08/01/16 Initial release R02 10/31/16 Drive Belt Alignment procedure added, Driven Clutch Retaining Bolt torque updated. R03 11/30/16 Battery Terminal Bolt and 900 / 1000 Intake Plenum Hose Clamp torque updated R04 12/08/16 Compressor Drive Belt Replacement Video added. R05 2017 VEHICLE UPDATES APPLICABLE MODEL VEHICLE SYSTEM UPDATE DESCRIPTION XP 1000 Models Engine New engine option, HVAC option added XP 1000 Models Drivetrain Propshaft CV Joints XP 1000 Models Electrical Drive Mode options added For more detailed information on vehicle updates, refer to the applicable Model Year Update training module at: www.mytrainingandrewards.com .

2015–2017 RANGER XP/CREW 570/900/1000 Service Manual Chapter Summary CHAPTER 1: GENERAL INFORMATION CHAPTER 2: MAINTENANCE CHAPTER 3: ENGINE / COOLING SYSTEM CHAPTER 4: FUEL SYSTEM CHAPTER 5: PVT SYSTEM CHAPTER 6: TRANSMISSION CHAPTER 7: FINAL DRIVE CHAPTER 8: STEERING / SUSPENSION CHAPTER 9: BRAKE SYSTEM CHAPTER 10: BODY / FRAME CHAPTER 11: ELECTRICAL

1 9927645 R04 - 2015–2017 RANGER XP/CREW 570/900/1000 Service Manual © Copyright Polaris Industries Inc. 1.1 GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION REFERENCE INFORMATION ........................................................................... 1.2 SERVICE RULES...................................................................................... 1.2 PUBLICATION NUMBERS ............................................................................. 1.3 REPLACEMENT KEYS ................................................................................ 1.4 SPECIAL TOOLS WEBSITE ........................................................................... 1.5 SPECIAL TOOLS INDEX............................................................................... 1.6 MASTER TORQUE LIST.............................................................................. 1.17 VEHICLE IDENTIFICATION ............................................................................ 1.22 MODEL NUMBER DESIGNATION .................................................................... 1.22 ENGINE DESIGNATION NUMBER.................................................................... 1.22 VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION........................................... 1.22 VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS .............................................. 1.23 VEHICLE SPECIFICATIONS ........................................................................... 1.24 2015-2016 RANGER XP 570 / EPS OVERVIEW....................................................... 1.24 2015-2016 RANGER XP 570 / EPS SPECIFICATIONS ................................................ 1.25 2015-2016 RANGER XP CREW 570 / EPS OVERVIEW ............................................... 1.26 2015-2016 RANGER XP CREW 570 / EPS SPECIFICATIONS ......................................... 1.27 2015-2017 RANGER XP 900 / EPS OVERVIEW....................................................... 1.28 2015-2017 RANGER XP 900 / EPS SPECIFICATIONS ................................................ 1.29 2015-2017 RANGER CREW XP 900 / EPS OVERVIEW ............................................... 1.30 2015-2017 RANGER CREW XP 900 / EPS SPECIFICATIONS ......................................... 1.31 2016 RANGER XP 900 HIGH LIFTER OVERVIEW .................................................... 1.32 2016 RANGER XP 900 HIGH LIFTER SPECIFICATIONS .............................................. 1.33 2017 RANGER XP 1000 / EPS OVERVIEW ........................................................... 1.34 2017 RANGER XP 1000 / EPS SPECIFICATIONS ..................................................... 1.35 2017 RANGER CREW XP 1000 / EPS OVERVIEW .................................................... 1.36 2017 RANGER CREW XP 1000 / EPS SPECIFICATIONS ............................................. 1.37 2017 RANGER XP 1000 HIGH LIFTER OVERVIEW ................................................... 1.38 2017 RANGER XP 1000 HIGH LIFTER SPECIFICATIONS ............................................ 1.39 2017 RANGER CREW XP 1000 HIGH LIFTER OVERVIEW............................................ 1.40 2017 RANGER CREW XP 1000 HIGH LIFTER SPECIFICATIONS ..................................... 1.41 CLUTCH CHART ..................................................................................... 1.42 MISC. SPECIFICATIONS AND CHARTS .............................................................. 1.43 CONVERSION TABLE ................................................................................ 1.43 STANDARD BOLT TORQUE SPECIFICATION ........................................................ 1.44 METRIC BOLT TORQUE SPECIFICATION ............................................................ 1.44 SAE TAP / DRILL SIZES .............................................................................. 1.45 METRIC TAP / DRILL SIZES .......................................................................... 1.45 DECIMAL EQUIVALENTS ............................................................................ 1.46

1.2 9927645 R04 - 2015–2017 RANGER XP/CREW 570/900/1000 Service Manual © Copyright Polaris Industries Inc. REFERENCE INFORMATION SERVICE RULES In order to perform service work efficiently and prevent costly errors, technicians should read the text in this manual and familiarize themselves with the procedures before beginning. Notes, Cautions and Warnings have been included for clarification of text and safety concerns. Knowledge of mechanical theory, tool use and shop procedures are necessary to perform some procedures in this manual safely and correctly. Use only genuine Polaris service parts, including fasteners that require replacement if removed. Do NOT substitute fasteners or hardware. Cleanliness of parts and tools as well as the work area is of primary importance. Dirt and foreign matter will cause damage to precision parts. Clean the vehicle before beginning service. Clean all parts before installing. If difficulty is encountered in removing or installing a component, look to see if a cause for the difficulty can be found. If it is necessary to tap the part into place, use a soft face hammer and tap lightly. Always follow torque specifications as outlined throughout this manual. Incorrect torquing may lead to serious machine damage or in the case of steering, driveline, and chassis components, can result in loss of control during operation of the vehicle, which may result in severe personal injury or death. If a torquing sequence is indicated for nuts, bolts or screws of a certain component, start all fasteners and hand tighten. Following the method and sequence indicated, tighten evenly to the specified torque value. When removing nuts, bolts or screws from a component with several fasteners, loosen them all about 1/4 turn before removing them to prevent distortion of that component. Replace all oil seals, sealing washers, gaskets, and O-rings with new ones during assembly. Be sure the mating surfaces for the gasket are clean and smooth to avoid leaks and maintain specified tolerances. Some procedures require removal of retaining rings or clips. Removal can weaken and deform these parts, therefore, they should always be replaced with new parts. When installing new retaining rings and clips, use care not to expand or compress them beyond what is required for installation. Polaris lubricants and greases have been specially formulated to provide maximum performance and protection when applied properly. In some applications, warranty coverage may be void if improper lubricants are used. Parts requiring grease should be cleaned thoroughly and fresh grease applied before reassembly. Deteriorating grease loses lubricity and may contain abrasive foreign matter. Always replace locking hardware such as lock nuts or lock washers, fasteners that have pre-applied locking agent, or any other fasteners as noted in this service manual with genuine Polaris hardware from an authorized Polaris dealer. Working with batteries can be hazardous. Review all battery warnings and cautions. GENERAL INFORMATION

9927645 R04 - 2015–2017 RANGER XP/CREW 570/900/1000 Service Manual © Copyright Polaris Industries Inc. 1.3 PUBLICATION NUMBERS MODEL MODEL NO. OWNER’S MANUAL 2015 RANGER 570 / EPS FULLSIZE R15RTA57AA, AC, AR / R15RTE57AU 9925545 2015 RANGER CREW 570 / EPS FULLSIZE R15RUA57AA / R15RUE57AC 9925545 2015 RANGER XP 900 / EPS R15RTA87AA, AC, AR / R15RTE87AA, AB, AK, AM, AR, AS, AV, AW, A2, A5 9925415 2015 RANGER CREW 900 / EPS R15RUA87AA, AR / R15RUE87AC, AM, AS, AW 9925415 2016 RANGER 570 / EPS FULLSIZE R16RTA57A1, A4, A9, B1, B4, B9 / R16RTE57AP, AU, BP, BU 9926460 2016 RANGER CREW 570 / EPS FULLSIZE R16RVA57A1, B1 / R16RVE57A9, B9 9926460 2016 RANGER XP 900 / EPS R16RTA87A1, A4, A9, B1, B4, B9 / R16RTE87A1, A4, A9, AK, AM, AS, AV, B1, B4, B9, BK, BM, BS, BV / R16RTM87AL, BL / R16RTU87A9, AB, AS, B9, BB, BS 9926461 2016 RANGER CREW 900 / EPS R16RUA87A1, B1 / R16RVA87A1, B1 / R16RUE87A9, AM, AS, AV, B9, BM, BS, BV / R16RVE87A9, AM, AS, AV, B9, BM, BS, BV 9926461 2017 RANGER XP 900 / EPS R17RTA87A1, A9, B1, B9 / R17RTE87A4, B4 9927168 2017 RANGER XP 900 EU R17RTE87F1, FU / R17RTS87F1 / FU 9927388 2017 RANGER XP 900 EPS EU R17RTS87C1, CU 9927390 2017 RANGER CREW XP 900 / EPS R17RVA87A1, B1 / R17RVE87A9, B9 9927168 2017 RANGER XP 1000 / EPS R17RTA99A1, B1 / R17RTE99A9, AS, AW, AY, B9, BS, BW, BY / R17RTU99AT, BT 9927168 2017 RANGER CREW XP 1000 / EPS R17RVA99A1, B1 / R17RVE99A9, AS, AY, B9, BS, BY, NY 9927168 2017 RANGER XP 1000 High Lifter R17RTM99AM, BM 9927392 2017 RANGER CREW XP 1000 High Lifter R17RVM99AM. BM 9927392 2017 RANGER XP 1000 Northstar R17RTU99AV, BV 9927174 2017 RANGER CREW XP 1000 Northstar R17RVU99AV, BV 9927174 NOTE When ordering service parts be sure to use the correct parts manual. Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com. GENERAL INFORMATION 1

1.4 9927645 R04 - 2015–2017 RANGER XP/CREW 570/900/1000 Service Manual © Copyright Polaris Industries Inc. REPLACEMENT KEYS Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. (i.e. In this example, the first two digits are 31 which would use key blank PN 4110141. SERIES# PART NUMBER 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 GENERAL INFORMATION

2015-2017 Polaris Ranger XP/CREW 570/900/1000 OEM Service & Repair Manual

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